This study has focused on solid oxide electrolyser cells for high temperature steam electrolysis. Solid oxide electrolysis is the reverse operation of solid oxide fuel cells (SOFC), so many of the same component materials may be used. However, other electrode materials are of interest to improve performance and efficiency. In this work anode materials were investigated for use in solid oxide electrolysers. Perovskite materials of the form L₁₋ｘSrｘMO₃ , where M is Mn, Co, or Fe. LSM is a well understood electrode material for the SOFC. Under electrolysis operation LSM performed well and no interface reactions were observed between the anode and YSZ electrolyte. LSM has a relatively low conductivity and the electrode reaction is limited to the triple phase boundary regions. Mixed ionic-electronic conductors of LSCo and LSF were investigated, with these materials the anode reaction is not limited to triple phase boundaries. The LSCo anode had adherence problems in the electrolysis cells due to the thermal expansion coefficient mismatch with the YSZ electrolyte. The LSCo reacted with the YSZ at the anode/electrolyte interface forming insulating zirconate phases. Due to these issues the LSCo anode cells performed the poorest of the three. The performance of electrolysis cells with LSF anode exceeded both LSM and LSCo, particularly under steam operation, although an interface reaction between the LSF anode and YSZ electrolyte was observed. In addition to the anode material studies this work included the development of solid oxide electrolyser tubes from tape cast precursor materials. Tape casting is a cheap processing method, which allows for co-firing of all ceramic components. The design development resulted in a solid design, which can be fabricated reliably, and balances strength with performance. The design used LSM anode, YSZ electrolyte, and Ni-YSZ cathode materials but could easily be adapted for the use of other component materials. Proper sintering rates, cathode tape formulation, tube length, tape thickness, and electrolyte thickness were factors explored in this work to improve the electrolyser tubes.

The demand for higher efficiency and cleaner power sources increases daily. The Direct Methanol Fuel Cells (DMFC) is one of those power sources that produces reliable electrical energy at high efficiencies and very low pollution levels. Remote telecommunication sites need power sources that can deliver reliable power. This dissertation informs the reader about the working principles of the DMFC and the materials it consists of. A good amount of theoretical background is also given on the DMFC, especially on the Membrane Electrode Assembly (MEA). Different membranes as well as their properties are discussed. Results from other researchers on DMFCs are also captured. A DMFC stack including a test rig, was built. The DMFC stack consisted of five single DMFC cells. Each cell contained an MEA, Gas Diffusion Layers (GDLS), highly corrosive resistant metal support grids, bipolar flow field plates and end plates. The DMFC stack was operated and tested in a test rig. The test rig held the air blower which supplied the cathode with the required oxidant (air), and the methanol solution tank plus its liquid pump. The liquid pump circulated the methanol solution through the anode side of the stack. It was observed that the DMFC is very susceptible to corrosion, especially if the methanol solution becomes conductive owing to solubility of C02 in it. Methanol itself is a corrosive substance. However the results obtained from the experiments clearly indicate that the DMFC can be implemented as an electrical power source for telecommunications.

O manganito de neodímio dopado com estrôncio (NSM) é um dos materiais catódicos alternativos e que estão sendo estudados e pesquisados para aplicação em células a combustível de óxido sólido de temperatura intermediária (ITSOFCs). O estrôncio (Sr) auxilia consideravelmente na condutividade elétrica e na proximidade do coeficiente de expansão térmica do NSM com os eletrólitos de céria gadolínia (GDC) e céria samária (SDC), e que tornam o material adequado ao uso em temperaturas entre 500 e 800 ºC. Seguindo este contexto, o presente trabalho é uma contribuição ao estudo da síntese de NSM com diferentes concentrações molares de Sr (10, 30 e 50 %), através da técnica de reação no estado sólido. Os materiais foram obtidos e caracterizados visando avaliá-los quanto às características adequadas para emprego na ITSOFC. Após a síntese dos pós e processamento do material sinterizado, avaliou-se principalmente o teor do dopante Sr para a identificação das composições químicas obtidas, estrutura cristalina formada, morfologia dos pós e cerâmicas, além da expansão térmica e condutividade elétrica do material sinterizado. Verificou-se que os valores das concentrações molares dos elementos químicos constituintes para a formação do NSM estão próximos dos valores calculados estequiometricamente antes da etapa de calcinação. A porosidade se mostrou mais adequada para as amostras sinterizadas a 1100 e a 1200 ºC. Comprovou-se que, o teor de dopante não altera significativamente a área de superfície específica e o valor das densidades. Os coeficientes de expansão térmica encontrados estão bastante próximos aos eletrólitos comerciais e verificou-se que com o aumento das concentrações molares de estrôncio, ocorre o acréscimo nos valores de coeficientes de expansão térmica. A condutividade elétrica está adequada para aplicação como material catódico. Os resultados mostram que a síntese por mistura de sólidos apesar de ter as suas desvantagens, quando realizada com cuidados, proporciona pós de NSM, com boas características físicas, químicas e microestruturais. Conclui-se que as características do material com composição de 30 % em mol de Sr é a mais adequada para a preparação de suspensões cerâmicas para posterior deposição no eletrólito sólido de GDC e/ou SDC, embora sejam necessários outros estudos das características deste material como dispositivo eletroquímico para aplicação em ITSOFCs. / The strontium-doped neodymium manganite (NSM) is one of the alternative cathodic materials and they have been studied and searched for application in intermediate temperature solid oxide fuel cells (ITSOFCs). The strontium (Sr) assists considerably in the electric conductivity and in the proximity of the thermal expansion of the NSM with electrolytes of ceria doped with gadolinium (GDC) or samarium (SDC), allowing them to become the adequate material for the use in temperatures between 500 and 800 ºC. Following this context, the present work is a contribution to the study of the synthesis of NSM with different molar concentrations of Sr (10, 30 and 50 %), through the technique of solid state reaction. The materials were obtained and characterized to be adjusted to the requested characteristics for operating in the ITSOFC. After the synthesis of the powders and processing the sintered material, it was evaluated the concentration of Sr for the identification of chemical compositions, crystalline structure, powders morphology and ceramics, besides the thermal expansion and electric conductivity of the sintered material. It was verified that the values of the molar concentrations of the constituent chemical elements of the NSM are close to the values theoretically calculated before the stage of calcination. The porosity showed to be more adequate for the samples sintered at 1100 and 1200 ºC. One proved that, the increase of the Sr, relatively little, diminishes the specific surface area and the value of the densities and the coefficients of thermal expansion of the sintered samples. The found coefficients of thermal expansion are sufficiently close to the ones of commercial electrolytes and the electric conductivity is adequate for a cathodic application as material. The results show that the synthesis by solid state reaction, although having its disadvantages, provides powders of NSM with good physical, chemical and microstructural characteristics when carried with certain cares. It is concluded that the composition of 30 % in mol of Sr and sintered at 1200 ºC is the best for the preparation of ceramic suspensions for posterior deposition on the solid electrolyte of GDC and/or SDC, even so further studies are necessary to completely adjust this material to be used in a electrochemical device for application in ITSOFCs.

O manganito de neodímio dopado com estrôncio (NSM) é um dos materiais catódicos alternativos e que estão sendo estudados e pesquisados para aplicação em células a combustível de óxido sólido de temperatura intermediária (ITSOFCs). O estrôncio (Sr) auxilia consideravelmente na condutividade elétrica e na proximidade do coeficiente de expansão térmica do NSM com os eletrólitos de céria gadolínia (GDC) e céria samária (SDC), e que tornam o material adequado ao uso em temperaturas entre 500 e 800 ºC. Seguindo este contexto, o presente trabalho é uma contribuição ao estudo da síntese de NSM com diferentes concentrações molares de Sr (10, 30 e 50 %), através da técnica de reação no estado sólido. Os materiais foram obtidos e caracterizados visando avaliá-los quanto às características adequadas para emprego na ITSOFC. Após a síntese dos pós e processamento do material sinterizado, avaliou-se principalmente o teor do dopante Sr para a identificação das composições químicas obtidas, estrutura cristalina formada, morfologia dos pós e cerâmicas, além da expansão térmica e condutividade elétrica do material sinterizado. Verificou-se que os valores das concentrações molares dos elementos químicos constituintes para a formação do NSM estão próximos dos valores calculados estequiometricamente antes da etapa de calcinação. A porosidade se mostrou mais adequada para as amostras sinterizadas a 1100 e a 1200 ºC. Comprovou-se que, o teor de dopante não altera significativamente a área de superfície específica e o valor das densidades. Os coeficientes de expansão térmica encontrados estão bastante próximos aos eletrólitos comerciais e verificou-se que com o aumento das concentrações molares de estrôncio, ocorre o acréscimo nos valores de coeficientes de expansão térmica. A condutividade elétrica está adequada para aplicação como material catódico. Os resultados mostram que a síntese por mistura de sólidos apesar de ter as suas desvantagens, quando realizada com cuidados, proporciona pós de NSM, com boas características físicas, químicas e microestruturais. Conclui-se que as características do material com composição de 30 % em mol de Sr é a mais adequada para a preparação de suspensões cerâmicas para posterior deposição no eletrólito sólido de GDC e/ou SDC, embora sejam necessários outros estudos das características deste material como dispositivo eletroquímico para aplicação em ITSOFCs. / The strontium-doped neodymium manganite (NSM) is one of the alternative cathodic materials and they have been studied and searched for application in intermediate temperature solid oxide fuel cells (ITSOFCs). The strontium (Sr) assists considerably in the electric conductivity and in the proximity of the thermal expansion of the NSM with electrolytes of ceria doped with gadolinium (GDC) or samarium (SDC), allowing them to become the adequate material for the use in temperatures between 500 and 800 ºC. Following this context, the present work is a contribution to the study of the synthesis of NSM with different molar concentrations of Sr (10, 30 and 50 %), through the technique of solid state reaction. The materials were obtained and characterized to be adjusted to the requested characteristics for operating in the ITSOFC. After the synthesis of the powders and processing the sintered material, it was evaluated the concentration of Sr for the identification of chemical compositions, crystalline structure, powders morphology and ceramics, besides the thermal expansion and electric conductivity of the sintered material. It was verified that the values of the molar concentrations of the constituent chemical elements of the NSM are close to the values theoretically calculated before the stage of calcination. The porosity showed to be more adequate for the samples sintered at 1100 and 1200 ºC. One proved that, the increase of the Sr, relatively little, diminishes the specific surface area and the value of the densities and the coefficients of thermal expansion of the sintered samples. The found coefficients of thermal expansion are sufficiently close to the ones of commercial electrolytes and the electric conductivity is adequate for a cathodic application as material. The results show that the synthesis by solid state reaction, although having its disadvantages, provides powders of NSM with good physical, chemical and microstructural characteristics when carried with certain cares. It is concluded that the composition of 30 % in mol of Sr and sintered at 1200 ºC is the best for the preparation of ceramic suspensions for posterior deposition on the solid electrolyte of GDC and/or SDC, even so further studies are necessary to completely adjust this material to be used in a electrochemical device for application in ITSOFCs.

The development of an index to compare different sources of energy is presented; the index address the appraisal of the source of energy from its sustainable performance and also using the factors that influence the user's decision making process of adopting an alternative energy. The index is used to compare the fuel cell system and the traditional grid system powered by coal fired power plants, for a typical residential unit located in the rural Appalachian region in Ohio.

The metallic alloys employed in oxidizing environment at high temperature rely on the development of a protective oxide scale to sustain the long-term aggressive exposition. However, the oxide scale growth is most of the time coupled with stress and morphological developments limiting its lifetime and then jeopardizing the metallic component reliability. In this study, a mechanism of local stress effect on the oxidation kinetics at the metal/oxide interface is investigated. The objective is to improve the understanding on the possible interactions between stress generation and non-uniform oxide scale growth, which might result in a precipitated mechanical failure of the system. Two different oxides are studied, alumina and chromia, in two different industrial systems, thermal barrier coatings and solid oxide fuel cell interconnects. A specific thermodynamic treatment of local oxide phase growth coupled with stress generation is developed. The formulation is completed with a phenomenological macroscopic framework and a numerical simulation tool is developed allowing for realistic analyses. Two practical situations are simulated and analyzed, concerning an SOFC interconnect and a thermal barrier coating system, for which oxide scale growth and associated stress and morphological developments are critical. The consequence of the non-uniform oxide growth on the system resistance to mechanical failure is investigated. Finally, the influences of material-related properties are studied, providing optimization directions for the design of metallic alloys which would improve the mechanical lifetime of the considered systems.

In view of the unfavorable panorama of actual energy supply practices, alternative sustainable energy sources and conversion approaches have acquired noteworthy significance in recent years. Among these, proton exchange membrane fuel cells (PEMFCs) are being considered as a pivotal building block in the transition towards a sustainable energy economy. The proton exchange membrane (PEM) is a vital component, as well as a performance-limiting factor, of the PEMFC. Consequently, the development of high performance PEM materials is of upmost importance for the advance of the PEMFC field. In this work, alternative PEM materials based on semi-interpenetrated networks from blends of poly(vinyledene fluoride) (PVDF) and sulfonated crosslinked acrylic polyelectrolytes (PE), as well as tri-phase PVDF/PE/zirconium-based composites, are studied. To alleviate the burden resulting from the vast number of possible combinations of the different precursors utilized in the preparation of the membranes, custom high throughput screening systems have been developed for their characterization. By coupling the data spaces obtained via these systems with the appropriate statistical and data analysis tools it was found that, despite not being directly involved in the proton transport process, the inert PVDF phase plays a major role on proton conductivity. Particularly, a univocal inverse correlation between the PVDF crystalline characteristics (i.e., crystallinity and crystallite size) and melt viscosity, and membrane proton conductivity was discovered. Membranes based on highly crystalline and viscous PVDF homopolymers exhibited reduced proton conductivity due to precluded segmental motion of the PE chains during crosslinking. In addition, a maximum effective amount of PE (55-60wt%) beneficial for proton conductivity was revealed. In the case of composite membranes, despite the fact that nanoparticle dispersion was thermodynamically limited, a general improvement in proton conductivity was evidenced at low to medium nanoparticle loadings (0.5 to 1wt%) in comparison to non-hybrid PVDF/PE references. This beneficial effect was particularly noticeable in membranes based on PVDF homopolymers (7% to 14.3% increment), where the nanoparticles induced a "healing" effect by providing proton-conducting paths between non-crosslinked PE channels separated by dense PVDF areas resulting from large PVDF crystallites. In general, the results presented herein are promising for the development of new cost-effective alternative PEMs.

Three-phase porous composites containing electrolyte (ionic conductor), electronic conductor, and porosity phases are frequently used for solid oxide fuel cell (SOFC) electrodes. Performance of such electrodes is microstructure sensitive. Topological connectivity of the microstructural phases and total length of triple phase boundaries are the key microstructural parameters that affect the electrode performance. These microstructural attributes in turn depend on numerous process parameters including relative proportion, mean sizes, size distributions, and morphologies of the electrolyte and electronic conductor particles in the powder mix used for fabrication of the composites. Therefore, improvement of the performance of SOFC composite electrodes via microstructural engineering is a complex multivariate problem that requires considerable input from microstructure modeling and simulations. This dissertation presents a new approach for geometric modeling and simulation of three-dimensional (3D) microstructure of three-phase porous composites for SOFC electrodes and provides electrode performance optimization guidelines based on the parametric studies on the effects of processing parameters on the total length and topological connectivity of the triple phase boundaries. The model yields an equation for total triple phase boundary length per unit volume (LTPB) that explicitly captures the dependence of LTPB on relative proportion of electrolyte and electronic conductor phases; volume fraction of porosity; and mean size, coefficient of variation, and skewness of electrolyte and electronic conductor particle populations in the initial powder mix. The equation is applicable to electrolyte and electronic conductor particles of any convex shapes and size distributions. The model is validated using experimental measurements performed in this research as well as the measurements performed by other researchers. Computer simulations of 3D composite electrode microstructures have been performed to further validate the microstructure model and to study topological connectivity of the triple phase boundaries in 3D microstructural space. A detailed parametric analysis reveals that (1) non-equiaxed plate-like, flake-like, and needle-like electrolyte and electronic conductor particle shapes can yield substantially higher LTPB; (2) mono-sized electrolyte and electronic conductor powders lead to higher LTPB as compared to the powders having size distributions with large coefficients of variation; (3) LTPB is inversely proportional to the mean sizes of electrolyte and electronic conductor particles; (4) a high value of LTPB is obtained at the lowest porosity volume fraction that permits sufficient connectivity of the pores for gas permeability; and (5) LTPB is not sensitive to the relative proportion of electrolyte and electronic conductor phases in the composition regime of interest in composite electrode applications.

Fuel cells have the potential to change the energy paradigm by allowing more efficient use of energy. In particular, Polymer Electrolyte Membrane Fuel Cells (PEMFC) are interesting because they are low temperature devices. However, there are still numerous challenges limiting their widespread use including operating temperature, types of permissible fuels and optimal use of expensive catalysts. The first two problems are related mainly to the ionomer electrolyte, which largely determines the operating temperature and fuel type. While new ionomer membranes have been proposed to address some of these issues, there is still a lack of fundamental knowledge to guide ionomer design for PEMFC. This work is a computational study of the effect of temperature and water content on sulfonated poly(ether ether ketone) and the effect of acidity on sulfonated polystyrene to better understand how ionomer material properties differ. In particular we found that increased water content preferentially solvates the sulfonate groups and improves water and hydronium transport. However, we found that increasing an ionomer’s acid strength causes similar effects to increasing the water content. Finally, we used Density Functional Theory (DFT) to study platinum nano-clusters as used in PEMFCs. We developed a model using the atom’s coordination number to quickly compute the energy of a cluster and therefore predict which platinum atoms are most loosely held. Our model correctly predicted the energy of various clusters compared to DFT. Also, we studied the interaction between the various moieties of the electrolyte including the catalyst particle and developed a force field. The coordination model can be used in a molecular dynamics simulation of the three phase region of a PEMFC to generate unbiased initial clusters. The force field developed can be used to describe the interaction between this generated cluster and the electrolyte.

High temperature proton conducting perovskite oxides are very attractive materials for applications in electrochemical devices, such as solid oxide fuel cells (SOFCs) and hydrogen permeation membranes. A better understanding of the hydrogen oxidation mechanism over the metal/proton conductor interface, is critical for rational design to further enhance the performances of the applications. However, kinetic studies focused on the metal/proton system are limited, compared with the intensively studied metal/oxygen ion conductor system, e.g., Ni/YSZ (yttrium stabilized zirconia, Zr₁-ₓYₓO₂-δ). This work presents an elementary kinetic model developed to assess reaction pathway of hydrogen oxidation/reduction on metal/proton conductor interface. Individual rate expressions and overall hydrogen partial pressure dependencies of current density and polarization resistance were derived in different rate limiting cases. The model is testified by tailored experiments on Pt/BaZr₀.₁Ce₀.₇Y₀.₁Yb₀.₁O₃-δ (BZCYYb) interface using pattern electrodes. Comparison of electrochemical testing and the theoretical predictions indicates the dissociation of hydrogen is the rate-limiting step (RLS), instead of charge transfer, displaying behavior different from metal/oxygen ion conductor interfaces. The kinetic model presented in this thesis is validated by high quantitative agreement with experiments under various conditions. The discovery not only contributes to the fundamental understanding of the hydrogen oxidation kinetics over metal/proton conductors, but provides insights for rational design of hydrogen oxidation catalysts in a variety of electrochemical systems.